Tufting method and apparatus



Jan. 16, 1962 N. JOHNSON TUFTING METHOD AND APPARATUS 4 Sheets-Sheet 1 Filed Sept.' 12, 1958 INVENTOR.

NELS JOHNSON ATTORNEYS Jan. 16, 1962 N. JOHNSON 3,016,852

TUFTING METHOD AND APPARATUS Filed Sept. 12, 1958 4 Sheets-Sheet z INVENTOR.

NELS JOHNSON BY jaw 4 513x724 ATTORNEYS 1952 N. JOHNSON 3,016,852

TUFTING METHOD AND APPARATUS Filed Sept. 12, 1958 4 Sheets-Sheet 3 INVENT OR.

NELS .aormsorv BY ATTORNEYS 1952 N. JOHNSON 3,016,852

TUFTING METHOD AND APPARATUS Filed Sept. 12, 1958 FIG. 6

4 Sheets-Sheet 4 INVENTOR.

NELS JOHNSON BY ATTORNEYS nitd States Patent Ofiiee 3,016,852 Patented Jan. 16, 1952 3,016,852 TUFTING METHOD AND APPARATUS Nels Johnson, Kenosha, Wis, assignor to Simmons Company, New York, N.Y., a corporation of Delaware Fiied Sept. 12, 1958, Ser. No. 760,583 1 Claim. (Cl. 112-262) This invention relates generally to the tufting of mattresses and similar articles, and more particularly to an improved method for tufting mattresses and to apparatus for carrying out the improved mattress tufting process.

The methods and apparatus commonly employed heretofore in the tufting of mattresses have often resulted in an indeterminate or casual lateral displacement of opposed portions of the upper and lower mattress faces during the tufting operation. Such displacement produces an unsightly appearance and reduced saleability because a tuft so produced distorts the mattress, producing a nonrectangular cross section. In addition, if the tufts are intended to be aligned within a specified area, such a in a stripe in the ticking, with random lateral displacement of the mattress faces frequently results in a failure to properly locate the tufts on at least one of the mattress faces.

Accordingly, the present invention is directed to the elimination of these unsatisfactory results and has for its principal object the provision of a new and improved method for tufting mattresses, and other like articles.

A further object of the present invention is to provide a method for tufting mattresses which substantially prevents relative lateral displacement between the opposed mattress faces and which results uniformly in the formation of accurately aligned tufts on the opposed mattress faces.

Another object of the present invention is the provision of imp ed a paratus for tufting mattresses in accordance with the improved method described herein.

Other objects and advantages of the present invention will be understood by the reference to the following description and the accompanying drawings which illustrate one embodiment of an apparatus constructed for the tufting of mattresses in accordance with the invention.

In the drawings:

FIGURE 1 is a side elevational view of a mattress tufting machine which is especially adapted to carry out the novel tufting method of the invention;

FIGURE 2 is an enlarged fragmentary elevational view of a portion of the machine shown in FIGURE 1, illustrating the mechanism which effects compression of the mattress from its underside;

FIGURE 3 is a fragmentary plan view of the mechanism shown in FIGURE 2;

FIGURE 4 is a sectional view taken along line 44 of FIGURE 3, and showing the cam and cam follower which actuate the lower compression mechanism;

FIGURE 5 is a view similar to FIGURE 4, showing the action of the cam and cam follower;

FIGURES 6 to 11 are fragmentary sectional views of a mattress and the adjacent portions of the apparatus for carrying out the method, showing in successive stages, the tufting of a mattress in accordance with the method of the invention.

The present invention may be employed to produce the desired tnfting effect shown in FIGURE 11, wherein there is illustrated a mattress 21 having opposed faces 23 and 25 which, for convenience, shall be respectively referred to as the upper face and lower face. A tufting cord or twine 27 extends through the mattress and has tied to its ends upper and lower tufting buttons 29 and 31 which bear, respectively, against the upper and lower mattress faces. Of course, if desired, a tuft may be formed at each of the ends of the cord 27 instead of attaching a 2 tufting button. As used herein, the terms tuft and tufting button are employed interchangeably.

In the practice of the present invention, the region of the mattress 21 to be tufted is compressed or displaced, at vertically aligned positions, thereon, from both the upper and lower mattress faces 23 and '25 to form a Zone of reduced thickness in the mattress. The tufting cord 27 is then passed through the zone of reduced thickness while maintaining the displaced condition of the opposed regions of the upper and lower mattress faces. Subsequently, a tufting button is attached at each end of the tufting cord and the inwardly displaced condition of the mattress faces is relieved to place the tufting cord under tension and to thereby produce the desired tufting effect. Best results have been achieved, when using the above described method, by simultaneously effecting the compression of the upper and lower mattress faces.

The tufting method generally described above may be effectively and eificiently performed on a mattress tufting machine which is indicated by the numeral 41 in FIG URE 1, and which comprises a base 43 supporting a frame or housing 4-5 upon which are carried a lower operating head 47 and an overhanging arm 49. The overhanging arm 49 supports an upper operating head 51 in opposed and spaced relation to the lower head 47. The mattress 21 to be tufted is positioned in a carriage 53, or other suitable support, between the upper and lower heads 51 and 47, and the latter include portions which are movable relative to the mattress to apply the described compression for the execution of the tuft in accordance with the described method.

More particularly, the upper head 51 includes a generally vertically reciprocable compression member or foot 55 having a needle guide 57, and a conventional button tying unit 59 which includes a button hopper or magazine 61. The lower head 47 incorporates a lower corn pression member or yoke 62 having generally vertically reciprocal motion and a button tying unit 65 including a magazine or a hopper 67 similar to the unit 59 incorporated in the upper head 51. Extending vertically through the lower head 47 is a needle 69 which is guided for generally vertical reciprocating travel by a tubular guide 71 carried on the forward portion of the frame 45.

The various operating components are driven by means of an electric motor 73 mounted on the base 43, and are sequentially operated in a predetermined relation through suitable drive mechanism. In this regard, the motor 73 drives a cross shaft 75 by means of a belt connection 77. Mounted on the cross shaft '75 is a drive pinion '79 which meshes with a driven gear 81 on a transverse shaft 83. Also mounted on the cross shaft 75 is a clutch mechanism (not illustrated) which may be disengaged by the movement of the lever arm 85 to permit manual operation of the machineby the use of the hand wheel 87 if particular circumstances require such manual operation.

The movements and operations of the needle 69 and the upper compression foot 55 are coordinated with the operations of the upper and lower tying units 59 and 65 and withthe movements of the lower compression yoke 63 through the transverse shaft 83. In this regard, the transverse shaft 83 carries a driving gear 8% which meshes with a camming gear 91 on a shaft 93 to effect the operation of the needle 69 and the upper compression foot 55. In addition, the transverse shaft 83 also carries a worm 95 which drives a worm gear 97 on a longitudinally extending shaft 99 to effect operation of the lower compression yoke 63 and the upper and lower tying units 59 and 65.

The upper compression foot 55 is driven from the camming gear 91 by a linkage including a lever arm 101 which is pivotally connected at one end to the frame about the pivot pin 163. The lever arm 101 carries a cam follower or roller 105 which travels in a suitable camway formed in the side surface of the camming gear 91 and indicated at 107. Adjustably connected to the other end of the lever arm 101 is a clevis member 109 which in turn is pivotally joined to a connecting rod 111. The connecting rod 111 is pivotally attached to one of the arms of a bell crank 113 which is pivotally mounted to the frame about the pivot 115. A bar 117 is pivotally connected at one of its ends to the other arm of the bell crank 113 and includes a rack 119 adjacent its forward end which meshes with an idler pinion 121. The pinion 121 drives a rack member 123 which supports the upper compression foot 55. Accordingly, movement of the lever arm 101 which results from the travel of the cam follower 105 effects a predetermined vertical reciprocating movement of the upper compression foot 55.

The needle 69 is also driven by the cam gear 91 through a linkage which includes a rocker arm 125 mounted on a fulcrum 127. The rearward portion of the rocker arm 125 carries a cam follower or roller 129 which travels in a suitable camway provided in the side of the cam gear 91 and indicated at 131. The forward end of the rocker arm 125 has pivotally connected thereto a link 133 which is joined to a lever 135 pivoted at one end for rocking motion about the fulcrum 127. The other or forward end of the lever 135 includes a suitable lost motion connection with the needle 69 whereby the rocking of the lever 135, which results from the travel of the cam follower 129 along the camway 131, causes vertical reciprocating motion of the needle 69 from a retracted position within the lower head 47, through the mattress 21 and needle guide 57, to a projecting position within the upper head 51.

The upper and lower button tying units 59 and 65 are driven in synchronism with the other tuft tying components by the longitudinal shaft 99. In this regard, the forward end of the longitudinal shaft 99 is connected, through an adjustable coupling 137, with a drive sprocket 139 carrying a chain 141 which drives a sprocket 143 carried by an operating cam shaft 145 for the lower button tying unit 65.

The upper button tying unit 59 is driven by a connection extending from the other end of the longitudinal shaft 99 which includes a sprocket 147 carrying an endless chain driving a second sprocket 149 carried on a shaft 151 positioned generally parallel to the shaft 99. The forward end of the shaft 151 connects with an adjustable coupling 153 which drives an operating cam shaft 155 for the upper button tying unit 59.

The cam shafts 155 and 145, associated respectively with the upper and lower button tying units 59 and 65, operate in the usual manner to effect attachment of the buttons by grasping the associated free end of the tufting cord and knotting the tufting cord about a loop provided on the button. In addition, the cam shaft 145 also operates to effect cutting of the tufting cord at the proper time by the lower button tying unit 65.

The lower compression member or yoke 63 which cooperates with the upper compression foot 55 to provide the initial compression or collapse of the mattress21 is connected to and operated, as can be best seen in FIGURES 2 and 3, by means of a rocker or lever arm 161 which in turn is driven by the longitudinally extending shaft 99. In this connection, the lever arm 161 is pivotally supported by means of a pin 163 (FIG. 3) to an anchor post 165 which is suitably attached, as by bolting, to the lower button tying unit 65. The rearward end of the rocker arm 161 has suitably secured thereto a bracket 167 which carries a cam 169 (FIGS. 4 and having a camming surface 171. Fixedly supported on the drive shaft 99 is a twopiece sleeve or collar 173 which carries a roller 175 in position for engagement with the cam 169.

As can be seen best in FIGURES 4 and 5, the collar 173 includes a half section 177 which is bolted or otherwise suitably secured to another half section 179 in a manner which affords a frictional grip of the drive shaft 99. The half section 173 carries a pin 181 upon which the roller is mounted for engagement with the cam 169 to effect rocking of the lever arm 161.

The other end of the rocker arm 161 is connected to the compression yoke 63 through an adjusting means, such as the turnbuckle 183 (FIG. 2), and a pair of clevis members 185 and 187. The compression yoke 63 includes an upper section 191 having a pair of fingers 193 and a leg 195 at right angles to the upper section 191 which carries the clevis member 185. The compression yoke 63 is guided for linear movement in a direction generally perpendicular to the mattress faces by means of a guide means which comprises a slide or guide 197 suitably attached, such as by bolting, to one side of the lower button tying unit. A U-shaped bracket 199 is bolted or otherwise suitably attached to the leg 195 of the compression yoke 63 to surround the slide 197 and to thereby guide the travel of the yoke 63 for vertical reciprocal movement incident to the rocking of the lever arm 161.

The retracted position of the compression yoke 63 is determined by engagement of the lower surface of the fingers 193 against the upper face of the button tying unit 65. The compression yoke 63 is biased in this position by a suitable means which in the illustrated arrangement takes the form of a spring 201 attached between the frame 45 and the end of the rocker arm 161 connected to the compression yoke. In the retracted compression yoke position the relation of the collar 173 and the cam 169 is as illustrated in FIG. 4. In addition to positioning the compression yoke 63 against the upper surface of the button tying unit 65, the action of the spring 201 also yieldably restrains the upward motion of the compression yoke 63 which results from the engagement of the roller 175 against the earn 169.

The inwardly directed angle of engagement of the roller 175 against the inclined surface 171 of the cam 169 may tend to turn or bend the rocker arm 161 inwardly toward the drive shaft 99. In order to prevent this eventuality, an angle iron 203 extends upwardly from the frame and carries a hardened wear plate 205 which engages the inner surface of the rocker arm to prevent cocking or bending of the rocker arm.

As previously indicated, the lower compression yoke 63 is driven, in coordination with the upper compression yoke 55 and the other operating components, by engagement of the roller 175 against the cam 169. In this regard, as the roller travels along the cam 169, the lever arm 161 is rocked first in the counter-clockwise direction against the action of the spring 201 to raise or elevate the compression yoke 63 and is then rocked clockwise under the influence of the spring 201 until the compression yoke 63 is fully withdrawn or retracted. This motion of the rocker arm 161 is imparted through the turnbuckle 183 and clevis members 185 and 187 to the compression yoke 63 which reciprocates vertically along the slide 197. As can be readily understood, the length of the upward travel of the compression yoke 63 may be adjusted by means of the turnbuckle 183. In addition, the action of the compression yoke 63 can also be adjusted and correlated with the other operating components of the tufting machine by adjustment of the collar 173 about the drive shaft 99 or by suitable alterations of the cam 169 to obtain any desired throw and/or sequential performance.

The improved mattress tufting method and the overall operation of the disclosed machine in the performance of the disclosed tufting method may be most clearly understood with reference to FIGURES 6 through 11.

In this regard, FIGURE 6 illustrates the mattress 21 carried on the carriage 53 and positioned between the upper and lower operating heads 51 and 47 prior to the tufting operation. As illustrated therein, at the beginning of the machine operating cycle, the upper compression foot 55 and the lower compression yoke 63 are fully retracted. The needle 59 is also fully withdrawn within the lower head.

As the tufting operation begins, the upper compression foot 55 and the lower compression yoke 63 are driven toward one another so that opposed portions of each of the mattress faces are simultaneously inwardly displaced toward each other as shown in FIGURE 7. Inward displacement of both mattress faces stabilizes the mattress for the piercing of the needle and also minimizes the length of travel through the mattress to permit the execution of a tuft having upper and lower buttons in proper aligned relation to the mattress faces. In addition, inward displacement of both the mattress faces to substantially the same extent acts to prevent cross-sectional distortion and to retain the desired rectangular shape. Thus, when the needle 69 rises, it pierces the mattress and passes a tufting cord through vertically aligned portions of the lower and upper mattress faces, to thereby eliminate the condition of misalignment which often results when previous tufting methods are used.

As shown in FIGURE 8, after the needle 69 has threaded the tufting cord 27 through the mattress, the lower compression yoke 63 is fully retracted to relieve the inwardly displaced condition of the lower mattress face 25. However, retraction of the lower compression yoke 63 can be delayed until later in the sequence of opera tion, if desired. At about the same time as the yoke 63 is retracted, the upper compression foot 55 is partially retracted to effect a partial release of the inwardly displaced condition of the upper mattress face 23 so as to position the upper face of the mattress at a preselected level above the lower button tying unit to thereby determine the proper length of tufting cord. As the upper compression foot and lower compression yoke are retracted, the needle 59 enters the upper head 51 and the upper button tying operation takes place.

After completion of the attachment of the upper button 29 to the tufting cord, the needle 69 withdraws through the mattress. The resultant tension on the tufting cord 27, which accompanies witndrawa] of the needle, effects release of the upper button 2) from the upper tying unit 59. The continued retraction of the needle 69 causes the cord to be drawn tautly through the mattress and positions the button 29 on the upper mattress face 23, as shown in FIGURE 9. The partially depressed condition of the upper mattress face, which is determined by the position of the upper compression foot, coupled with the taut condition of the tufting cord, which positions the button on the upper mattress face, enables severing of the tufting cord by the lower tying unit to provide a sufiicient cord length to alford attachment of the lower button and to properly complete the tufting operation. After the cord is severed, the lower button tying unit begins to attach the lower button 31.

As shown in FIGURE it), after the lower button tying operation has begun, the upper compression foot travels downwardly to further inwardly displace the mat-tress in order to ar'ford sufficient additional cord length to complete the tying operation and to produce a tuft in which the length of cord between the attached upper and lower buttons is less than the thickness of the mattress. When the attachment of the botom button 31 to the tufting cord is completed, the upper compression foot is then fully retracted to place the tufting cord under tension between the upper and lower faces of the mattress and to produce the desired tuft as shown in FIGURE 11.

Although the tufting operation which is illustrated in FIGURES 6 through 11 is shown with the tufting cord located centrally of a spring contained between the mattress faces, it should be understood that the tufts may be located in random relation to the mattress springs and that the central location of the tuft relative to the illustrated spring is not essential to secure the advantages of the present invention.

Utilization of the disclosed novel tufting method is eifecitve to uniformly and reliably produce a series of tufts in a mattress, or other similar article, without causing or producing an unsatisfactory lateral shifting of the opposed mattress faces resulting in undesirable distortion of the preferred rectangular mattress cross section.

Various changes and modifications may be made in the disclosed construction to achieve certain of the features mentioned herein without departing from the principles of the invention.

I claim:

The method of tufting a mattress comprising the siniultancous compressing of the mattress for the execution of a tuft by substantially displacing opposed portions of the faces of the mattress toward each other to produce a local zone of reduced thickness intermediate the facial planes of the mattress, passing a needle having an eye threaded with a tufting cord through the zone of reduced thickness while maintainnig said compression, releasing the depression of one face of the mattress, partially releasing the depression of the other face of the mattress, tying a first button to the end of the tufting cord extending beyond the other face, reracting the needle to position the button against the other face of the mattress, severing the cord, increasing the compression applied to the other face so as to increase the inward displacement of the other face, tying a second button to the other end of the card, the distance between said buttons being less than the original thickness of the mattress and releasing the compressed condition of the other face of the mattress to thereby place the tufting cord under tension with the buttons in engagement with the respectively opposed faces of the mattress.

References Cited in the file of this patent UNITED STATES PATENTS 797,399 Bent Aug. 15, 1905 819,952 Thompson May 8, 1906 1,922,211 Mathewson Aug. 15, 1933 1,947,2l7 Micon Feb. 13, 1934 2,048,348 Mathewson July 21, 1936 2,089,252 Droll et al Aug. 10, 1937 2,098,785 Mathewson Nov. 9, 1937 2,100,844 Foster Nov. 30, 1937 2,146,084 Morley Feb. 7, 1939 2,466,696 Garrigus Apr. 5, 1949 

